Flow through gauge for drill bit

ABSTRACT

An apparatus that includes one or more flow channels and method for fabricating such flow channels. The apparatus includes a body, one or more blades from one end of the body, and a corresponding gauge section disposed adjacently and in alignment with a respective blade. Each gauge section includes a leading section, a trailing section, a face section extending from one end of the leading section to an end of the trailing section, and at least one flow channel extending from the leading edge section to at least one of the trailing edge section or the face section.

RELATED APPLICATIONS

U.S. Provisional Application No. 61/709,063, entitled “Flow Through Gauge For Drill Bit” and filed on Oct. 2, 2012 is hereby incorporated by reference in its entirety.

U.S. Non-Provisional patent application Ser. No. 14/034,653, entitled “Blade Flow PDC Bits” and filed on Sep. 24, 2013, and U.S. Non-Provisional patent application Ser. No. 14/034,733, entitled “Machined High Angle Nozzle Sockets For Steel Body Bits” and filed on Sep. 24, 2013, are both hereby incorporated by reference.

BACKGROUND

This invention relates generally to drill bits and/or other downhole tools. More particularly, this invention relates to drill bits that include one or more flow management channels formed within one or more gauge sections of the drill bits and/or other downhole tools.

FIG. 1 shows a perspective view of a drill bit 100 in accordance with the prior art. Referring to FIG. 1, the drill bit 100 includes a bit body 110 that is coupled to a shank 115 and is designed to rotate in a counter-clockwise direction 190. The shank 115 includes a threaded connection 116 at one end 120. The threaded connection 116 couples to a drill string (not shown) or some other equipment that is coupled to the drill string. The threaded connection 116 is shown to be positioned on the exterior surface of the one end 120. This positioning assumes that the drill bit 100 is coupled to a corresponding threaded connection located on the interior surface of a drill string (not shown). However, the threaded connection 116 at the one end 120 is alternatively positioned on the interior surface of the one end 120 if the corresponding threaded connection of the drill string (not shown) is positioned on its exterior surface in other exemplary embodiments. A bore (not shown) is formed longitudinally through the shank 115 and the bit body 110 for communicating drilling fluid from within the drill string to a drill bit face 111 via one or more nozzles 114 during drilling operations.

The bit body 110 includes a plurality of gauge sections 150 and a plurality of blades 130 extending from the drill bit face 111 of the bit body 110 towards the threaded connection 116, where each blade 130 extends to and terminates at a respective gauge section 150. The blade 130 and the respective gauge section 150 are formed as a single component, but are formed separately in certain drill bits 100. The drill bit face 111 is positioned at one end of the bit body 110 furthest away from the shank 115. The plurality of blades 130 form the cutting surface of the drill bit 100. One or more of these plurality of blades 130 are either coupled to the bit body 110 or are integrally formed with the bit body 110. The gauge sections 150 are positioned at an end of the bit body 110 adjacent the shank 115. The gauge section 150 includes one or more gauge cutters (not shown) in certain drill bits 100. The gauge sections 150 typically define and hold the full hole diameter of the drilled hole. Each of the blades 130 and gauge sections 150 include a leading edge section 152, a face section 154, and a trailing edge section 156. The face section 154 extends from one end of the trailing edge section 156 to an end of the leading edge section 152. The leading edge section 152 faces in the direction of rotation 190, while the trailing edge faces in the opposite direction of rotation 190. A junk slot 122 is formed between each consecutive blade 130, which allows for cuttings and drilling fluid to return to the surface of the wellbore (not shown) once the drilling fluid is discharged from the nozzles 114. A plurality of cutters 140 are coupled to each of the blades 130 and extend outwardly from the surface of the blades 130 to cut through earth formations when the drill bit 100 is rotated during drilling. One type of cutter 140 used within the drill bit 100 is a PDC cutter; however other types of cutters are contemplated as being used within the drill bit 100. The cutters 140 and portions of the bit body 110 deform the earth formation by scraping and/or shearing depending upon the type of drill bit 100. Although one embodiment of the drill bit has been described, other drill bit embodiments or other downhole tools that include one or more gauge sections, which are known to people having ordinary skill in the art, are applicable to exemplary embodiments of the present invention.

During drilling of a borehole, the drill bit 100 rotates to cut through an earth formation to form a wellbore therein. This cutting is typically performed through scraping and/or shearing action according to certain drill bits 100, but is performed through other means based upon the type of drill bit used. Drilling fluid (not shown) exits the drill bit 100 through one or more nozzles 114 and facilitates the removal of the cuttings from the borehole wall back towards the surface. As the drill bit 110 rotates and the drilling fluid with cuttings are at the bottom of the borehole, the gauge section 150 is eroded rapidly, which also causes the surface of the gauge section 150 to become rounded. Further, the cuttings are re-grinded, which thereby generated additional heat and reduces the cooling function performed by the drilling fluid on the blades 130 and on the gauge section 150.

Gauge pad wear is a primary limiter of drill bit life. Cuttings regrinding, caused by cuttings getting squeezed into the small gap that can open up during drilling between the gauge pad and the borehole wall, acts to significantly increase cuttings regrinding and wear. In standard smooth gauge pad design, the faces of the gauge pads constitute a hydraulic “dead zone” limiting hydraulic cooling and accelerating thermal induced deterioration of the gauge pad surfaces.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and aspects of the invention will be best understood with reference to the following description of certain exemplary embodiments of the invention, when read in conjunction with the accompanying drawings, wherein:

FIG. 1 shows a perspective view of a drill bit in accordance with the prior art;

FIG. 2 shows a perspective view of a drill bit including one or more flow channels in a gauge section of the drill bit in accordance with an exemplary embodiment of the present invention;

FIG. 3 shows a schematic view of the one or more flow channels in the gauge section of the drill bit of FIG. 2 in accordance with an exemplary embodiment of the present invention;

FIG. 4 shows a perspective view of a drill bit including one or more flow channels in a gauge section of the drill bit in accordance with an exemplary embodiment of the present invention;

FIG. 5 shows a schematic view of the one or more flow channels in the gauge section of the drill bit of FIG. 4 in accordance with an exemplary embodiment of the present invention;

FIG. 6 shows a perspective view of a drill bit including one or more flow channels in a gauge section of the drill bit in accordance with an exemplary embodiment of the present invention;

FIG. 7 shows a schematic view of the one or more flow channels in the gauge section of the drill bit of FIG. 6 in accordance with an exemplary embodiment of the present invention;

FIG. 8 shows a perspective view of a drill bit including one or more flow channels in a gauge section of the drill bit in accordance with an exemplary embodiment of the present invention;

FIG. 9 shows a schematic view of the one or more flow channels in the gauge section of the drill bit of FIG. 8 in accordance with an exemplary embodiment of the present invention;

FIG. 10 shows a perspective view of a drill bit including one or more flow channels in a gauge section of the drill bit in accordance with an exemplary embodiment of the present invention;

FIG. 11 shows a schematic view of the one or more flow channels in the gauge section of the drill bit of FIG. 10 in accordance with an exemplary embodiment of the present invention;

FIG. 12 shows a perspective view of a drill bit including one or more flow channels in a gauge section of the drill bit in accordance with an exemplary embodiment of the present invention;

FIG. 13 shows a schematic view of the one or more flow channels in the gauge section of the drill bit of FIG. 12 in accordance with an exemplary embodiment of the present invention;

FIG. 14 shows a perspective view of a drill bit including one or more flow channels in a gauge section of the drill bit in accordance with an exemplary embodiment of the present invention;

FIG. 15 shows a schematic view of the one or more flow channels in the gauge section of the drill bit of FIG. 14 in accordance with an exemplary embodiment of the present invention;

FIG. 16 shows a perspective view of a drill bit including one or more flow channels in a gauge section of the drill bit in accordance with an exemplary embodiment of the present invention;

FIG. 17 shows a schematic view of the one or more flow channels in the gauge section of the drill bit of FIG. 16 in accordance with an exemplary embodiment of the present invention;

FIG. 18 shows a perspective view of a drill bit including one or more flow channels in a gauge section of the drill bit in accordance with an exemplary embodiment of the present invention; and

FIG. 19 shows a schematic view of the one or more flow channels in the gauge section of the drill bit of FIG. 18 in accordance with an exemplary embodiment of the present invention.

The drawings illustrate only exemplary embodiments of the invention and are therefore not to be considered limiting of its scope, as the invention may admit to other equally effective embodiments.

DETAILED DESCRIPTION

This invention relates generally to drill bits and/or other downhole tools. More particularly, this invention relates to drill bits that include one or more flow management channels formed within one or more gauge sections of the drill bits and/or other downhole tools. Although the description provided below is related to a fixed cutter bit, exemplary embodiments of the invention relate to any downhole tool having one or more gauge sections, such as, but not limited to, steel body or matrix PDC bits, impregnated bits, and other fixed cutter bits.

According to exemplary embodiments of the present invention, one or more inlet holes are deployed on a leading edge section adjacent to a gauge section of a bit. Further one or more outlet holes are deployed on one or more of the face section and/or a trailing edge section, where one or more outlet holes are fluidly coupled to at least one inlet hole. The outlet hole and the corresponding inlet hole form a fluid channel extending therebetween. The fluid channels are deployed to allow fluid to flow beneath at least a portion of the face section of the gauge section to provide cooling to the face section. Alternatively, the fluid channels are deployed to allow fluid to flow along at least a portion of the face section of the gauge section, also providing cooling to the face section. These fluid channels are deployed at an upward angle, in certain exemplary embodiments, to facilitate the movement of entrained cuttings and drilling fluid in the uphole direction. However, in other exemplary embodiments, one or more fluid channels are deployed in a horizontal direction or a downward angle.

FIG. 2 shows a perspective view of a drill bit 200 including one or more flow channels 360 in a gauge section 250 of the drill bit 200 in accordance with an exemplary embodiment of the present invention. FIG. 3 shows a schematic view of the one or more flow channels 360 in the gauge section 250 of the drill bit 200 in accordance with an exemplary embodiment of the present invention. Referring to FIGS. 2 and 3, the drill bit 200 is similar to drill bit 100 (FIG. 1) and includes a bit body 210 that is coupled to a shank 215. The drill bit 200 is designed to rotate in a counter-clockwise direction 290. The shank 215 includes a threaded connection (not shown) at one end (not shown). This threaded connection is similar to threaded connection 116 (FIG. 1). The threaded connection couples to a drill string (not shown) or some other equipment that is coupled to the drill string. A bore (not shown) is formed longitudinally through the shank and the bit body 210 for communicating drilling fluid from within the drill string to a drill bit face 211 via one or more nozzles 214 during drilling operations.

The bit body 210 includes a plurality of gauge sections 250 and a plurality of blades 230 extending from the drill bit face 211 of the bit body 210 towards the shank 215, where each blade 230 extends to and terminates at a respective gauge section 250. The blade 230 and the respective gauge section 250 are formed as a single component, but are formed separately in other drill bits. The drill bit face 211 is positioned at one end of the bit body 210 furthest away from the shank 215. The plurality of blades 230 form the cutting surface of the drill bit 200. One or more of these plurality of blades 230 are either coupled to the bit body 210 or are integrally formed with the bit body 210. The gauge sections 250 are positioned at an end of the bit body 210 adjacent the shank 215. The gauge section 250 includes one or more gauge cutters (not shown) in certain exemplary embodiments of drill bits. The gauge sections 250 typically define and hold the full hole diameter of the drilled hole. Each of the blades 230 and gauge sections 250 include a leading edge section 252, a face section 254, and a trailing edge section 256. The face section 254 extends from one end of the trailing edge section 256 to an end of the leading edge section 252 and forms a front surface of the gauge section 250. The leading edge section 252 faces in the direction of rotation 290, while the trailing edge section 256 faces in the opposite direction of rotation 290. A junk slot 222 is formed between each consecutive blade 230, which allows for cuttings and drilling fluid to return to the surface of the wellbore (not shown) once the drilling fluid is discharged from the nozzles 214. A plurality of cutters 240 are coupled to each of the blades 230 and extend outwardly from the surface of the blades 230 to cut through earth formations when the drill bit 200 is rotated during drilling. One type of cutter 240 used within the drill bit 200 is a PDC cutter; however, other types of cutters are contemplated as being used within the drill bit 200. The cutters 240 and portions of the bit body 210 deform the earth formation by scraping and/or shearing depending upon the type of drill bit 200.

According to some exemplary embodiments, as shown in FIGS. 2 and 3, one or more inlet holes 270 are formed within the leading edge section 252 and one or more outlet holes 275 are formed within the trailing edge section 256. The flow channel 360 extends from an inlet hole 270 to at least one corresponding outlet hole 275. Hence, the drilling fluid and/or cuttings enter into the flow channel 360 through the inlet hole 270 and exits through the outlet hole 275. The fluid flowing through this flow channel 360 facilitates cooling of the gauge section 250 and also reduces erosion of the gauge section 250. In some exemplary embodiments, one inlet hole 270 corresponds to a single outlet hole 275. However, in other exemplary embodiments, one inlet hole 270 corresponds and is fluidly communicable to a plurality of outlet holes 275. Also, in certain exemplary embodiments, one or more outlet holes 275 is shaped and/or dimensioned differently than the corresponding inlet hole 270. For example, the outlet hole 275 is sized larger, in perimeter or diameter, than the corresponding inlet hole 270. This feature reduces plugging within the flow channel 360. In certain exemplary embodiments, at least one flow channel 360 is directed in an upward angle from the inlet hole 270 to the outlet hole 275. In other exemplary embodiments, the flow channel 360 is directed substantially horizontally or in a downward direction towards the bottom of the borehole (not shown). Hence, in this exemplary embodiment, the fluid flow within the flow channel 360 is beneath the face section 254.

FIG. 4 shows a perspective view of a drill bit 400 including one or more flow channels 560 in a gauge section 450 of the drill bit 400 in accordance with an exemplary embodiment of the present invention. FIG. 5 shows a schematic view of the one or more flow channels 560 in the gauge section 450 of the drill bit 400 in accordance with an exemplary embodiment of the present invention. Referring to FIGS. 4 and 5, the drill bit 400 is similar to drill bit 200 (FIG. 2). However, gauge section 450 is different from gauge section 250 (FIG. 2) in that the flow channel 560 is different than the flow channel 360 (FIG. 3). Each of the gauge sections 450 and blades 230, as described above with respect to drill bit 200 (FIG. 2), include a leading edge section 452, a face section 454, and a trailing edge section 456. The face section 454 extends from one end of the trailing edge section 456 to an end of the leading edge section 452 and forms a front surface of the gauge section 450. The leading edge section 452 faces in the direction of rotation 490 of the drill bit 400, while the trailing edge section 456 faces in the opposite direction of rotation 490.

According to some exemplary embodiments, as shown in FIGS. 4 and 5, one or more inlet holes 470 are formed within the leading edge section 452 and one or more outlet holes 475 are formed within the face section 454. The flow channel 560 extends from an inlet hole 470 to at least one corresponding outlet hole 475. Hence, the drilling fluid and/or cuttings enter into the flow channel 560 through the inlet hole 470 and exits through the outlet hole 475. The fluid flowing through this flow channel 560 facilitates cooling of the gauge section 450 and also reduces erosion of the gauge section 450. In some exemplary embodiments, one inlet hole 470 corresponds to and is in fluid communication with a single outlet hole 475. However, in other exemplary embodiments, one inlet hole 470 corresponds to and is in fluid communication with a plurality of outlet holes 475. Also, in certain exemplary embodiments, one or more outlet holes 475 is shaped and/or dimensioned differently than the corresponding inlet hole 470. For example, the outlet hole 475 is sized larger, in perimeter or diameter, than the corresponding inlet hole 470. This feature reduces plugging within the flow channel 560. In certain exemplary embodiments, at least one flow channel 560 is directed in an upward angle from the inlet hole 470 to the outlet hole 475. In other exemplary embodiments, the flow channel 560 is directed substantially horizontally or in a downward direction towards the bottom of the borehole (not shown).

FIG. 6 shows a perspective view of a drill bit 600 including one or more flow channels 760 in a gauge section 650 of the drill bit 600 in accordance with an exemplary embodiment of the present invention. FIG. 7 shows a schematic view of the one or more flow channels 760 in the gauge section 650 of the drill bit 600 in accordance with an exemplary embodiment of the present invention. Referring to FIGS. 6 and 7, the drill bit 600 is similar to drill bit 200 (FIG. 2). However, gauge section 650 is different from gauge section 250 (FIG. 2) in that the flow channel 760 is different than the flow channel 360 (FIG. 3). Each of the gauge sections 650 and blades 230, as described above with respect to drill bit 200 (FIG. 2), include a leading edge section 652, a face section 654, and a trailing edge section 656. The face section 654 extends from one end of the trailing edge section 656 to an end of the leading edge section 652 and forms a front surface of the gauge section 650. The leading edge section 652 faces in the direction of rotation 690 of the drill bit 600, while the trailing edge section 656 faces in the opposite direction of rotation 690.

According to some exemplary embodiments, as shown in FIGS. 6 and 7, one or more inlet holes 670 are formed within the leading edge section 652 and one or more outlet holes 675 are formed within the face section 654. Further, a deep groove 678 is formed within the face section 654 extending from the one or more outlet holes 675 to the trailing edge section 656. The deep groove 678 is substantially trapezoidal shaped in some exemplary embodiments; however, in other exemplary embodiments, the deep groove 678 is formed in any other geometric shape, such as rectangular or triangular, or non-geometric shape. The deep groove 678 is about ¼″ deep in some exemplary embodiments but is greater in depth in other exemplary embodiments. However, according to certain exemplary embodiments, deep groove 678 is less than ¼″ deep. In some exemplary embodiments, the depth of the deep groove 678 is substantially constant throughout the deep groove 678; however, the depth varies in other exemplary embodiments. For example, the depth of the deep groove 678 is shallower near the outlet holes 675 and deeper near the trailing edge section 656. The flow channel 760 extends from an inlet hole 670 to at least one corresponding outlet hole 675. Hence, the drilling fluid and/or cuttings enter into the flow channel 760 through the inlet hole 670 and exits through the outlet hole 675. The fluid flowing through this flow channel 760 facilitates cooling of the gauge section 650 and also reduces erosion of the gauge section 650. In some exemplary embodiments, one inlet hole 670 corresponds to and is in fluid communication with a single outlet hole 675. However, in other exemplary embodiments, one inlet hole 670 corresponds to and is in fluid communication with a plurality of outlet holes 675. Also, in certain exemplary embodiments, one or more outlet holes 675 is shaped and/or dimensioned differently than the corresponding inlet hole 670. For example, the outlet hole 675 is sized larger, in perimeter or diameter, than the corresponding inlet hole 670. This feature reduces plugging within the flow channel 760. In certain exemplary embodiments, at least one flow channel 760 is directed in an upward angle from the inlet hole 670 to the outlet hole 675. In other exemplary embodiments, the flow channel 760 is directed substantially horizontally or in a downward direction towards the bottom of the borehole (not shown).

FIG. 8 shows a perspective view of a drill bit 800 including one or more flow channels 960 in a gauge section 850 of the drill bit 800 in accordance with an exemplary embodiment of the present invention. FIG. 9 shows a schematic view of the one or more flow channels 960 in the gauge section 850 of the drill bit 800 in accordance with an exemplary embodiment of the present invention. Referring to FIGS. 8 and 9, the drill bit 800 is similar to drill bit 200 (FIG. 2). However, gauge section 850 is different from gauge section 250 (FIG. 2) in that the flow channel 960 is different than the flow channel 360 (FIG. 3). Each of the gauge sections 850 and blades 230, as described above with respect to drill bit 200 (FIG. 2), include a leading edge section 852, a face section 854, and a trailing edge section 856. The face section 854 extends from one end of the trailing edge section 856 to an end of the leading edge section 852 and forms a front surface of the gauge section 850. The leading edge section 852 faces in the direction of rotation 890 of the drill bit 800, while the trailing edge section 856 faces in the opposite direction of rotation 890.

According to some exemplary embodiments, as shown in FIGS. 8 and 9, one or more inlet holes 870 are formed within the leading edge section 852 and one or more outlet holes 875 are formed within both the face section 854 and the trailing edge section 856. The flow channel 960 extends from an inlet hole 870 to corresponding outlet holes 875, at least one formed in the face section 854 and at least one formed in the trailing edge section 856. Hence, the drilling fluid and/or cuttings enter into the flow channel 960 through the inlet hole 870 and exits through each of the corresponding outlet holes 875, one of which is positioned on the face section 854 and one of which is positioned on the trailing edge section 856. The fluid flowing through this flow channel 960 facilitates cooling of the gauge section 850 and also reduces erosion of the gauge section 850. In some exemplary embodiments, one inlet hole 870 corresponds to and is in fluid communication with a single outlet hole 875 on the face section 854 and a single outlet hole 875 on the trailing edge section 856. However, in other exemplary embodiments, one inlet hole 870 corresponds to and is in fluid communication with one outlet hole 875 on the face section 854, one outlet hole 875 on the trailing edge section 856, and at least one additional outlet hole 875 on either or both of the face section 854 and the trailing edge section 856. Also, in certain exemplary embodiments, one or more outlet holes 875 is shaped and/or dimensioned differently than the corresponding inlet hole 870. For example, the outlet hole 875 is sized larger, in perimeter or diameter, than the corresponding inlet hole 870. This feature reduces plugging within the flow channel 960. In certain exemplary embodiments, at least one flow channel 960 is directed in an upward angle from the inlet hole 870 to at least one outlet hole 875. In other exemplary embodiments, at least one flow channel 960 is directed substantially horizontally or in a downward direction towards the bottom of the borehole (not shown).

FIG. 10 shows a perspective view of a drill bit 1000 including one or more flow channels 1160 in a gauge section 1050 of the drill bit 1000 in accordance with an exemplary embodiment of the present invention. FIG. 11 shows a schematic view of the one or more flow channels 1160 in the gauge section 1050 of the drill bit 1000 in accordance with an exemplary embodiment of the present invention. Referring to FIGS. 10 and 11, the drill bit 1000 is similar to drill bit 200 (FIG. 2). However, gauge section 1050 is different from gauge section 250 (FIG. 2) in that the flow channel 1160 is different than the flow channel 360 (FIG. 3). Each of the gauge sections 1050 and blades 230, as described above with respect to drill bit 200 (FIG. 2), include a leading edge section 1052, a face section 1054, and a trailing edge section 1056. The face section 1054 extends from one end of the trailing edge section 1056 to an end of the leading edge section 1052 and forms a front surface of the gauge section 1050. The leading edge section 1052 faces in the direction of rotation 1090 of the drill bit 1000, while the trailing edge section 1056 faces in the opposite direction of rotation 1090.

According to some exemplary embodiments, as shown in FIGS. 10 and 11, one or more inlet holes 1070 are formed within the leading edge section 1052 and one or more outlet holes 1075 are formed within both the face section 1054 and the trailing edge section 1056. Further, a deep groove 1078 is formed within the face section 1054 extending from the one or more outlet holes 1075 formed in the face section 1054 to the trailing edge section 1056. The deep groove 1078 is substantially trapezoidal shaped in some exemplary embodiments; however, in other exemplary embodiments, the deep groove 1078 is formed in any other geometric shape, such as rectangular or triangular, or non-geometric shape. The deep groove 1078 is about ¼″ deep in some exemplary embodiments but is greater in depth in other exemplary embodiments. However, according to certain exemplary embodiments, deep groove 1078 is less than ¼″ deep. In some exemplary embodiments, the depth of the deep groove 1078 is substantially constant throughout the deep groove 1078; however, the depth varies in other exemplary embodiments. For example, the depth of the deep groove 1078 is shallower near the outlet holes 1075 formed within the face section 1054 and deeper near the trailing edge section 1056. The flow channel 1160 extends from an inlet hole 1070 to corresponding outlet holes 1075, at least one formed in the face section 1054 and at least one formed in the trailing edge section 1056. Hence, the drilling fluid and/or cuttings enter into the flow channel 1160 through the inlet hole 1070 and exits through each of the corresponding outlet holes 1075, one of which is positioned on the face section 1054 and one of which is positioned on the trailing edge section 1056. The fluid flowing through this flow channel 1160 facilitates cooling of the gauge section 1050 and also reduces erosion of the gauge section 1050. In some exemplary embodiments, one inlet hole 1070 corresponds to and is in fluid communication with a single outlet hole 1075 on the face section 1054 and a single outlet hole 1075 on the trailing edge section 1056. However, in other exemplary embodiments, one inlet hole 1070 corresponds to and is in fluid communication with one outlet hole 1075 on the face section 1054, one outlet hole 1075 on the trailing edge section 1056, and at least one additional outlet hole 1075 on either or both of the face section 1054 and the trailing edge section 1056. Also, in certain exemplary embodiments, one or more outlet holes 1075 is shaped and/or dimensioned differently than the corresponding inlet hole 1070. For example, the outlet hole 1075 is sized larger, in perimeter or diameter, than the corresponding inlet hole 1070. This feature reduces plugging within the flow channel 1160. In certain exemplary embodiments, at least one flow channel 1160 is directed in an upward angle from the inlet hole 1070 to at least one outlet hole 1075. In other exemplary embodiments, at least one flow channel 1160 is directed substantially horizontally or in a downward direction towards the bottom of the borehole (not shown).

FIG. 12 shows a perspective view of a drill bit 1200 including one or more flow channels 1260 in a gauge section 1250 of the drill bit 1200 in accordance with an exemplary embodiment of the present invention. FIG. 13 shows a schematic view of the one or more flow channels 1260 in the gauge section 1250 of the drill bit 1200 in accordance with an exemplary embodiment of the present invention. Referring to FIGS. 12 and 13, the drill bit 1200 is similar to drill bit 200 (FIG. 2). However, gauge section 1250 is different from gauge section 250 (FIG. 2) in that the flow channel 1260 is different than the flow channel 360 (FIG. 3). Each of the gauge sections 1250 and blades 230, as described above with respect to drill bit 200 (FIG. 2), include a leading edge section 1252, a face section 1254, and a trailing edge section 1256. The face section 1254 extends from one end of the trailing edge section 1256 to an end of the leading edge section 1252 and forms a front surface of the gauge section 1250. The leading edge section 1252 faces in the direction of rotation 1290 of the drill bit 1200, while the trailing edge section 1256 faces in the opposite direction of rotation 1290.

According to some exemplary embodiments, as shown in FIGS. 12 and 13, one or more deep grooves 1278 are formed within the face section 1254 extending from the leading edge section 1252 to the trailing edge section 1256. The deep groove 1278 is substantially hour-glass shaped in some exemplary embodiments; however, in other exemplary embodiments, the deep groove 1278 is formed in any other geometric shape, such as rectangular, triangular, or inverted triangular shapes, or non-geometric shape. In some exemplary embodiments, the flow channel 1260 is wider at the leading edge section 1252 and the trailing edge section 1256, but narrower therebetween. Alternatively, the flow channel 1260 is narrower at the leading edge section 1252 and wider at the trailing edge section 1256. Further, in other exemplary embodiments, the flow channel 1260 is wider at the leading edge section 1252 and narrower at the trailing edge section 1256. The deep groove 1278 is about ¼″ deep in some exemplary embodiments but is greater in depth in other exemplary embodiments. However, according to certain exemplary embodiments, deep groove 1278 is less than ¼″ deep. In some exemplary embodiments, the depth of the deep groove 1278 is substantially constant throughout the deep groove 1278; however, the depth varies in other exemplary embodiments. For example, the depth of the deep groove 1278 is shallower near the leading edge section 1252 and deeper near the trailing edge section 1256. The deep grooves 1278 is formed by milling, casting, or using any other known technique. The flow channel 1260, defined by the one or more deep grooves 1278, extends from the leading edge section 1252 to the trailing edge section 1256. Hence, the drilling fluid and/or cuttings enter into the flow channel 1260 through the leading edge section 1252 and exits through the trailing edge section 1256. The fluid flowing through this flow channel 1260 facilitates cooling of the gauge section 1250 and also reduces erosion of the gauge section 1250. In certain exemplary embodiments, at least one flow channel 1260 is directed in an upward angle from the leading edge section 1252 to the trailing edge section 1256. In other exemplary embodiments, the flow channel 1260 is directed substantially horizontally or in a downward direction towards the bottom of the borehole (not shown). Here, the flow channel 1260 is disposed adjacently and along the face section 1254.

FIG. 14 shows a perspective view of a drill bit 1400 including one or more flow channels 1460 in a gauge section 1450 of the drill bit 1400 in accordance with an exemplary embodiment of the present invention. FIG. 15 shows a schematic view of the one or more flow channels 1460 in the gauge section 1450 of the drill bit 1400 in accordance with an exemplary embodiment of the present invention. Referring to FIGS. 14 and 15, the drill bit 1400 is similar to drill bit 200 (FIG. 2). However, gauge section 1450 is different from gauge section 250 (FIG. 2) in that the flow channel 1460 is different than the flow channel 360 (FIG. 3). Each of the gauge sections 1450 and blades 230, as described above with respect to drill bit 200 (FIG. 2), include a leading edge section 1452, a face section 1454, and a trailing edge section 1456. The face section 1454 extends from one end of the trailing edge section 1456 to an end of the leading edge section 1452 and forms a front surface of the gauge section 1450. The leading edge section 1452 faces in the direction of rotation 1490 of the drill bit 1400, while the trailing edge section 1456 faces in the opposite direction of rotation 1490.

According to some exemplary embodiments, as shown in FIGS. 14 and 15, one or more deep grooves 1478 are formed within the face section 1454 extending from the leading edge section 1452 to the trailing edge section 1456. The deep groove 1478 is substantially any non-geometric shape and forms one or more pods 1479 in some exemplary embodiments; however, in other exemplary embodiments, the deep groove 1478 is formed in any geometric shape still forming one or more pods 1479. The deep groove 1478 surrounds the pods 1479, or islands. In some exemplary embodiments, one or more pods 1479 are circular shaped, but are shaped into other geometric shape, such as oval, diamond, or square, or non-geometric shapes in other exemplary embodiments. The deep groove 1478 is about ¼″ deep in some exemplary embodiments but is greater in depth in other exemplary embodiments. However, according to certain exemplary embodiments, deep groove 1478 is less than ¼″ deep. In some exemplary embodiments, the depth of the deep groove 1478 is substantially constant throughout the deep groove 1478; however, the depth varies in other exemplary embodiments. For example, the depth of the deep groove 1478 is shallower near the leading edge section 1452 and deeper near the trailing edge section 1456. The deep grooves 1478 is formed by milling, casting, or using any other known technique. The flow channel 1460, defined by the one or more deep grooves 1478, extends from the leading edge section 1452 to the trailing edge section 1456 and surrounds the one or more pods 1479. Hence, the drilling fluid and/or cuttings enter into the flow channel 1460 through the leading edge section 1452, passes around the pods 1479, and exits through the trailing edge section 1456. The fluid flowing through this flow channel 1460 facilitates cooling of the gauge section 1450 and also reduces erosion of the gauge section 1450. In certain exemplary embodiments, at least one flow channel 1460 is directed in an upward angle from the leading edge section 1452 to the trailing edge section 1456. In other exemplary embodiments, the flow channel 1460 is directed substantially horizontally or in a downward direction towards the bottom of the borehole (not shown). Here, the flow channel 1460 is disposed adjacently and along the face section 1454.

FIG. 16 shows a perspective view of a drill bit 1600 including one or more flow channels 1660 in a gauge section 1650 of the drill bit 1600 in accordance with an exemplary embodiment of the present invention. FIG. 17 shows a schematic view of the one or more flow channels 1660 in the gauge section 1650 of the drill bit 1600 in accordance with an exemplary embodiment of the present invention. Referring to FIGS. 16 and 17, the drill bit 1600 is similar to drill bit 200 (FIG. 2). However, gauge section 1650 is different from gauge section 250 (FIG. 2) in that the flow channel 1660 is different than the flow channel 360 (FIG. 3). Each of the gauge sections 1650 and blades 230, as described above with respect to drill bit 200 (FIG. 2), include a leading edge section 1652, a face section 1654, and a trailing edge section 1656. The face section 1654 extends from one end of the trailing edge section 1656 to an end of the leading edge section 1652 and forms a front surface of the gauge section 1650. The leading edge section 1652 faces in the direction of rotation 1690 of the drill bit 1600, while the trailing edge section 1656 faces in the opposite direction of rotation 1690.

According to some exemplary embodiments, as shown in FIGS. 16 and 17, one or more deep grooves 1678 are formed within the face section 1654 extending from the leading edge section 1652 to the trailing edge section 1656. The deep groove 1678 is substantially rectangularly shaped, or linearly, in some exemplary embodiments; however, in other exemplary embodiments, the deep groove 1678 is formed in any other geometric shape, such as curve-shaped, triangular or inverted triangular shapes, or non-geometric shape. In some exemplary embodiments, the flow channel 1660 is wider at the leading edge section 1652 and the trailing edge section 1656, but narrower therebetween. Alternatively, the flow channel 1660 is narrower at the leading edge section 1652 and wider at the trailing edge section 1656. Further, in other exemplary embodiments, the flow channel 1660 is wider at the leading edge section 1652 and narrower at the trailing edge section 1656. The deep groove 1678 is about ¼″ deep in some exemplary embodiments but is greater in depth in other exemplary embodiments. However, according to certain exemplary embodiments, deep groove 1678 is less than ¼″ deep. In some exemplary embodiments, the depth of the deep groove 1678 is substantially constant throughout the deep groove 1678; however, the depth varies in other exemplary embodiments. For example, the depth of the deep groove 1678 is shallower near the leading edge section 1652 and deeper near the trailing edge section 1656. The deep grooves 1678 is formed by milling, casting, or using any other known technique. The flow channel 1660, defined by the one or more deep grooves 1678, extends from the leading edge section 1652 to the trailing edge section 1656. Hence, the drilling fluid and/or cuttings enter into the flow channel 1660 through the leading edge section 1652 and/or through the face section 1654 and exits through the trailing edge section 1656. The fluid flowing through this flow channel 1660 facilitates cooling of the gauge section 1650 and also reduces erosion of the gauge section 1650. In certain exemplary embodiments, at least one flow channel 1660 is directed in an upward angle from the leading edge section 1652 to the trailing edge section 1656. In other exemplary embodiments, the flow channel 1660 is directed substantially horizontally or in a downward direction towards the bottom of the borehole (not shown). Here, the flow channel 1660 is disposed adjacently and along the face section 1654. According to certain exemplary embodiments, none of the flow channels 1660 intersect with another flow channel 1660. However, in other exemplary embodiments, at least one flow channel 1660 intersects with at least one other flow channel 1660.

FIG. 18 shows a perspective view of a drill bit 1800 including one or more flow channels 1860 in a gauge section 1850 of the drill bit 1800 in accordance with an exemplary embodiment of the present invention. FIG. 19 shows a schematic view of the one or more flow channels 1860 in the gauge section 1850 of the drill bit 1800 in accordance with an exemplary embodiment of the present invention. Referring to FIGS. 18 and 19, the drill bit 1800 is similar to drill bit 200 (FIG. 2). However, gauge section 1850 is different from gauge section 250 (FIG. 2) in that the flow channel 1860 is different than the flow channel 360 (FIG. 3). Each of the gauge sections 1850 and blades 230, as described above with respect to drill bit 200 (FIG. 2), include a leading edge section 1852, a face section 1854, and a trailing edge section 1856. The face section 1854 extends from one end of the trailing edge section 1856 to an end of the leading edge section 1852 and forms a front surface of the gauge section 1850. The leading edge section 1852 faces in the direction of rotation 1890 of the drill bit 1800, while the trailing edge section 1856 faces in the opposite direction of rotation 1890.

According to some exemplary embodiments, as shown in FIGS. 18 and 19, one or more deep grooves 1878 are formed within the face section 1854 extending from the leading edge section 1852 to the trailing edge section 1856. The deep groove 1878 is substantially curved-shaped in some exemplary embodiments; however, in other exemplary embodiments, the deep groove 1878 is formed in any other geometric shape, such as linearly, triangular or inverted triangular shapes, or non-geometric shape. In some exemplary embodiments, the flow channel 1860 is wider at the leading edge section 1852 and the trailing edge section 1856, but narrower therebetween. Alternatively, the flow channel 1860 is narrower at the leading edge section 1852 and wider at the trailing edge section 1856. Further, in other exemplary embodiments, the flow channel 1860 is wider at the leading edge section 1852 and narrower at the trailing edge section 1856. The deep groove 1878 is about ¼″ deep in some exemplary embodiments but is greater in depth in other exemplary embodiments. However, according to certain exemplary embodiments, deep groove 1878 is less than ¼″ deep. In some exemplary embodiments, the depth of the deep groove 1878 is substantially constant throughout the deep groove 1878; however, the depth varies in other exemplary embodiments. For example, the depth of the deep groove 1878 is shallower near the leading edge section 1852 and deeper near the trailing edge section 1856. The deep groove 1878 is formed by milling, casting, or using any other known technique. The flow channel 1860, defined by the one or more deep grooves 1878, extends from the leading edge section 1852 to the trailing edge section 1856. Hence, the drilling fluid and/or cuttings enter into the flow channel 1860 through the leading edge section 1852 and/or through the face section 1854 and exits through the trailing edge section 1856. The fluid flowing through this flow channel 1860 facilitates cooling of the gauge section 1850 and also reduces erosion of the gauge section 1850. In certain exemplary embodiments, at least one flow channel 1860 is directed in an upward angle from the leading edge section 1852 to the trailing edge section 1856. In other exemplary embodiments, the flow channel 1860 is directed substantially horizontally or in a downward direction towards the bottom of the borehole (not shown). Here, the flow channel 1860 is disposed adjacently and along the face section 1854. According to certain exemplary embodiments, none of the flow channels 1860 intersect with another flow channel 1860. However, in other exemplary embodiments, at least one flow channel 1860 intersects with at least one other flow channel 1860.

In some of the above exemplary embodiments, the flow channel is linear when extending from the leading edge section to the trailing edge section and curved when extending from the leading edge section to the face section. However, the flow channel is linear or curved regardless of the endpoint of the flow channel in other exemplary embodiments. Some drill bits and/or downhole tools include flow channels that are of a combination of any of the above mentioned flow channels. Although not specifically recited in each of the exemplary embodiments, any feature of one of the exemplary embodiments described above is combinable with any other exemplary embodiment to form a different exemplary embodiment, which is contemplated to be included as another exemplary embodiment of the present invention.

Exemplary embodiments of this invention also are combinable with one or more “High Angle Nozzle” feature as disclosed, or similarly disclosed, within U.S. Non-Provisional patent application Ser. No. 14/034,733, entitled “Machined High Angle Nozzle Sockets For Steel Body Bits” and filed on Sep. 24, 2013, and/or one or more “Flow Through” blade features as disclosed within U.S. Non-Provisional patent application Ser. No. 14/034,653, entitled “Blade Flow PDC Bits” and filed on Sep. 24, 2013, both of which have previously been hereby incorporated by reference herein.

Although the invention has been described with reference to specific embodiments, these descriptions are not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention will become apparent to persons skilled in the art upon reference to the description of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. It is therefore, contemplated that the claims will cover any such modifications or embodiments that fall within the scope of the invention. 

1. A downhole tool, comprising: a body having a bore formed therein; a plurality of blades extending from a face of the body, the plurality of blades forming a cutting surface; a junk slot formed between each consecutive blade; a nozzle disposed in the body adjacent each junk slot and for discharging drilling fluid from the bore and up the respective junk slot; and a plurality of polycrystalline diamond compact (PDC) cutters coupled to each blade, spaced along each blade, and extending outwardly from a surface thereof for cutting through earth formations; and a plurality of gauge sections operable to define and hold a full diameter of a hole drilled by the downhole tool, each gauge section disposed adjacently and in alignment with a respective blade, each gauge section comprising: a leading edge section; a trailing edge section; and a face section extending from the leading edge section to the trailing edge section, wherein: a deep groove is formed across an outer surface of each face section from the respective leading edge section to the respective trailing edge section, and each deep groove is operable to receive the drilling fluid and cuttings therethrough.
 2. The downhole tool of claim 1, wherein each deep groove is oriented at an upward angle.
 3. The downhole tool of claim 1, wherein each deep groove is curved.
 4. The downhole tool of claim 1, wherein each deep groove has a depth of at least one-fourth inch.
 5. The downhole tool of claim 1, wherein each deep groove at the leading edge section and at the trailing edge section is wider than a portion of the respective deep groove therebetween.
 6. The downhole tool of claim 1, wherein a second deep groove is formed across an exterior surface of each face section and is parallel to the respective deep groove.
 7. The downhole tool of claim 1, wherein each deep groove is linear.
 8. The downhole tool of claim 1, wherein: each face section comprises a pod, and each deep groove surrounds the respective pod.
 9. The downhole tool of claim 8, wherein each pod is selected from the group consisting of circular-shaped, diamond-shaped, rectangular-shaped, triangular-shaped, and a non-geometric shape.
 10. The downhole tool of claim 1, wherein: a plurality of flow channels are formed through each blade, the flow channels are spaced along each blade, the flow channels each extend from a leading edge section to a trailing edge section of the respective blade, the flow channels extend beneath the cutters of the respective blade, and the flow channels are operable to receive the drilling fluid and cuttings therethrough.
 11. The downhole tool of claim 1, wherein each blade and each gauge section are formed integrally with the body.
 12. The downhole tool of claim 11, wherein the body is made from steel. 